Sustainable Gains Through Rapid Improvement

A consumer product client had a specific need for increasing output on constraint assets at strategic locations over a 4-month period. Client did not have the bandwidth or problem-solving maturity to address these gaps in-house.

Background: A consumer product client had a specific need for increasing output on constraint assets at strategic locations over a 4-month period. Client did not have the bandwidth or problem-solving maturity to address these gaps in-house.

Win: Defined as 5 to 10 points of OEE (not percent improvement) on the constraint assets over a 4-month period.

Assessment: PSbyM’s unique assessment process provided insight on losses, specific projects, PSbyM and site ownership of projects, deliverables for each project.

Project Support: As part of PSbyM’s Rapid Improvement Process , Milliken provided project ownership (where needed), project coaching, hands-on support, sustainment processes, and governance to make certain the sites were successful in the implementation.

Wins across the five strategic sites:

Keys to Success:

Project selection designed around length of engagement. More 6-week to 8-week projects. If projects were 6-months, they were out of scope.
Need to have more projects than 10 points of OEE. There will be headwinds.
Cadence of PSbyM support matched the needs of the implementation.
Weekly governance calls (showing performance) with site practitioners, site leadership, corporate leadership, PSbyM leadership. Must recognize and course correct quickly.
Partner with the sites and give them the credit.

Other Benefits:

Building internal capabilities of the team
Replication of improvements to other machines in site
Learning to see the value in Continuous Improvement
Building the understanding of power of full Operational Excellence System

Interested in experiencing similar process improvements at your facility? Learn more about the Milliken Rapid Improvement Process or any of our manufacturing consulting services .